Multidirectional multiple fold laminated product and method of making

ABSTRACT

A laminated map or other product having a plurality of adjacent rectangular panels, formed of a paperboard sheet and a pair of transparent sheets covering the paperboard sheet, with the transparent sheets joining all of the paperboard sheets into an integrated product. The panels are arranged in at least two rows of plural panels and a plurality of columns of panels. When the pairs of panels in the columns are accordion-folded in the direction of the columns, and are then folded to cause the panels of one row to overlie the panels of the other row, the product will fold into a compact stack without substantial resistance to movement into that configuration and will be substantially flat, and when the panels are temporarily folded into single stack compact random arrays, those arrays will be compact and substantially flat. A method of making a multidirectional, multiple fold laminated product is also described.

This application is a continuation, of application Ser. No. 08/383,057filed Feb. 3, 1995 now abandoned

For many years road maps have been printed on paper which is prefoldedinto a package of convenient size and shape. Typically such foldedpackages have been rectangular. In the past several years, laminatedmaps have been developed which have employed a series of rectangularpanels joined together in a side-by-side array, but which are foldableinto a rectangular package. Such maps have typically folded into arectangular package which is substantially greater in size (in planview) than most folded paper maps distributed in the United States.Further, because of the limitations of their design, available foldedlaminated maps open to a size which is very much smaller than the sizeof a typical paper map. That severely limits the size of the area to bedisplayed, or if not the size, then the scale of the area depicted. Thatmeans that the opportunity to display details is hampered. Furthermore,available multi-panel laminated maps, by their construction, are longand narrow.

It would be desirable to provide a laminated map which, when folded, ismore compact than currently available laminated maps, but which, whenopened, provides a substantially greater surface area, thereby toprovide room for greater detail and coverage in both the north-south andeast-west directions. It would also be desirable to provide a laminatedmap that has a greater size in the vertical dimension than ispractically possible with existing laminated maps, while stillpermitting folding of the map into a more compact package. It also wouldbe desirable to employ these characteristics in other products, such asgameboards, informational products, educational tools, etc.

It would also be desirable to provide an improved method for making suchproducts and maps.

SUMMARY OF THE INVENTION

In accordance with the present invention, an improved laminatedmultidirectional, multiple fold product and method of making same isprovided. The laminated product has a plurality of adjacent rectangularpanels, each displaying selected intelligence. Each panel comprises apaperboard sheet having a pair of display surfaces and a pair oftransparent sheets covering the paperboard sheet display surfaces andjoining all of the paperboard sheets of the product into an integratedlaminated product. The panels are arranged in at least two rows ofplural panels and a plurality of columns of panels, one from each row,each pair of panels in a row being spaced apart by a distance which isminimally equal to at least the total thicknesses of the panels in therow and each pair of panels in a column being spaced apart by asubstantially greater distance which is minimally equal to at least thethicknesses of the total number of panels comprising the product. As aresult, when the pairs of panels in the columns are accordion-folded inthe direction of the columns, and are then folded to cause the panels ofone row to overlie the panels of the other row, the product will so foldinto a compact stack without substantial resistance to movement intothat configuration and will be substantially flat; further, when thepanels are temporarily folded multidirectionally into single stackcompact random arrays, those arrays will be compact and substantiallyflat, and any surface of any panel may therefore be temporarily easilydisplayed for viewing.

In one form of the invention the product is a laminated map. The productpreferably has two rows, and each row has at least four rectangularpanels. The panels are desirably about 41/4 inches by about 9 inches insize. The paperboard sheet of each panel may be entirely separate fromeach other paperboard sheet. In a preferred form the distances betweenpanels is at least about 10 percent greater than the minimal distances.

An improved method of making a multidirectional, multiple fold,multi-row, multi-column laminated product in accordance with thisinvention comprises the steps of providing a rectangular paperboardsheet with intelligence printed on at least one side thereof, the sheethaving a leading edge, two perpendicular side edges and a trailing edgeparallel to the leading edge, feeding the leading edge of the sheet in afirst direction and cutting out a narrow transverse segment in themiddle of the sheet to produce a narrow transverse gap, leavingconnecting portions at each end of the transverse gap, the transversegap being parallel to the leading edge, gripping the paperboard sheetand feeding its leading edge in the same first direction andcontinuously cutting the paperboard sheet into adjacent panels in adirection parallel to the side edges and perpendicular to the leadingedge with cutters, thereby to remove strips of waste from betweenadjacent panels, and feeding the leading edge into a laminating rollernip with laminating sheets prior to cutting with the cutters into thezone of the transverse gap and continuously gripping the sheet betweenits side edges at a distance from the laminating roller nip that is lessthan the distance between the leading edge and the transverse gap.

In a preferred form, the method additionally comprises cutting selvagefrom the sides of the paperboard sheet to remove selvage and theconnecting portions, concurrently with the cutting of strips of wastefrom between adjacent panels. Laminating desirably continues until thetrailing edge passes through the laminating nip, following which theleading edge, the trailing edge and the side edges are trimmed toprovide finished edges.

Further objects, features and advantages of the present invention willbecome apparent from the following drawings and description.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an open, typical multidirectional,multiple fold product of the present invention, the product having tworows of four rectangular panels each;

FIG. 2 is an open, plan view of the product of FIG. 1;

FIG. 3 is a side elevational view of the product of FIG. 2;

FIG. 4 is a top elevational view of the product of FIG. 2;

FIG. 5 is a fragmentary cross-sectional view taken along line 5--5 ofFIG. 2;

FIG. 6 is a view of the product of FIG. 1 folded into a compact form;

FIG. 7 is an open, plan view of a further embodiment of a product of thepresent invention;

FIG. 8 is a schematic perspective view of a printed paperboard sheetbearing intelligence in the form of a map, illustrating stepwise theprocess of forming a compactly foldable map product of the presentinvention;

FIG. 9 is a fragmentary enlarged detailed view of a portion of FIG. 8;

FIG. 10 is a sectional view of the cutters and associated components ofFIG. 9; and

FIGS. 11 and 11B illustrate portions of the master paperboard sheet ofFIG. 8.

DETAILED DESCRIPTION

Integrated, laminated multidirectional, multiple foldable products 10 inaccordance with the present invention have multiple, spaced apartrectangular panels P1, P2 which are arrayed in both horizontal rows andvertical columns. Each panel is made up of a central, relatively stiff,paperboard sheet 12 having upper and lower display surfaces andwaterproof, transparent upper and lower outer laminating sheets 14, 16joining all of the sheets 12 into an integrated product. The upper andlower outer sheets are each integral sheets which extend across thepaperboard sheets 12 and across the spaces between them. The panelsdisplay selected intelligence which, in a map product, is ideallycomplete and continuous between adjacent panels. Of course the panelsmay display other selected intelligence, words, graphics, and the like,and may display inserts as well. Typically in a map at least some of theadjacent panels display continuous cartography.

The panels of the product 10 are spaced from adjacent panels bypredetermined distances which are greater between the rows than betweenadjacent panels in the same row. Thus, the array of multiple panels maybe folded multidirectionally into a relatively flat stacked condition,while providing a laminated map or like product which is not onlycompact, but which is capable of providing a display area which issubstantially greater than a comparable single row product can display.A typical display area is about 17 by 18 inches, with eight panelsfolding to a compact size of about 41/4 inches by 9 inches, a size whichconveniently fits into existing merchandizing racks, glove compartments,purses and pockets.

Importantly, for temporary use the map may be compactly foldedmultidirectionally into a stacked array in a variety of configurationsto compactly display either side of any panel, and the spaces betweenthe panels is selected and dimensioned so that the map may be so folded.Thus, the map may be temporarily folded in a variety of random arrays,with all of the panels in a single stack arranged to form a very compactpackage, thereby to easily temporarily display any desired panel surfacefor viewing.

As shown by the drawings, panels P1 in a first horizontal row R1 aredisposed adjacent panels P2 in a second horizontal row R2. Each pair ofadjacent panels P1, P2 defines a vertical column, of which four suchcolumns (C1, C2, C3 and C4) are illustrated in FIGS. 1 and 2. As will beappreciated, the distances D1 between adjacent panels P1 in the firsthorizontal row R1 (and between adjacent panels P2 in the secondhorizontal row R2) are of a first dimension, while the distance D2between the first and second rows R1, R2 is of a second dimensiongreater than distance D1.

Preferably distance D1 is minimally equal to at least total thethicknesses of the panels in a row, namely four times the thicknesses ofthe transparent sheets 14, 16 and paperboard sheet 12 making up eachpanel P1 and P2 of the product 10, whereas distance D2 is substantiallygreater, namely is minimally equal to at least the sum of thethicknesses of all of the panels P1 and P2 of the product 10. Thus, whenthe pairs of vertically adjacent panels P1, P2 in a column are foldedaccordion-style relative to each other, and the thusly folded array isfolded in half, the resulting stacked array is compact for storage andwill lie substantially flat, all without substantial resistance tomovement into that folded configuration. Further, when the panels of arow are folded in on each other, the resulting stacked array will stilllie substantially flat.

Although their dimensions may vary, in a preferred form the paperboardsheets are about 0.008 inch in thickness and the outer laminating sheetsare polyester and are of a thickness of 0.003 inch. The thicknesses ofthe paperboard sheets are about 22/3 times the thicknesses of eachplastic sheet. Of course other laminating sheets may be used, such aspolypropylene film sheets. In this embodiment the distance D1 isminimally about 0.056 inch, and the distance D2, where eight panels arepresent, is minimally about 0.112 inch. In a most preferred form thedistances D1 and D2 are at least about 10% more than the specifiedminimum. This provides for effective folding while allowing foridiosyncratic variations from product to product, all while keeping thespace between the adjacent edges of panels and the contiguousintelligence to a reasonable minimum.

The panels and laminating sheets are joined via a lamination process,and the resulting laminate may be trimmed around the border or perimeterto provide sharp, clean finished edges. The edges may be sealed edges,trimmed edges as illustrated by FIG. 5, or a combination of such edges.

In a most preferred form, the intelligence on the panels may be printedthereon, and may take the form of a map, as illustrated by FIGS. 1 and2. Desirably the intelligence is printed on the paperboard itself,which, as is clear from the foregoing, is then protected from theambient surroundings by the transparent, waterproof laminating sheets.Preferably, the paperboard sheets 12 are each separate elements as theyare laminated with the plastic sheets 14, 16, as a result of which theyare not joined together. Therefore there is no resistance to folding orbending resulting from connecting tabs or the like, as is the case withlaminated articles illustrated in FIGS. 1 and 2 of Howard U.S. Pat. No.5,063,637.

As shown by the drawings, the spaces between adjacent pairs of panelsare overlaid by portions of the transparent laminating sheets 14, 16.These portions of the sheets serve as hinges and, depending upon thelaminating process and the means used to laminate the paperboard andplastic sheets, may be joined or bonded to each other in the spaces D1,D2 between the paperboard elements of the panels or may be independentof, and spaced from, each other.

Referring now to FIG. 7, a further product 40 of the present inventionis illustrated. It comprises a series of panels P3 and P4 defining apair of spaced horizontal rows R3, R4 and a plurality of verticalcolumns, each containing a panel P3 and P4, like the columns of panelsof the embodiment of FIG. 1. In this case there are five pairs ofcolumns (rather than four). The columns are similarly adapted to beaccordion-folded, and then from that array to be folded over into acompact single layer of panels, just like the product of FIGS. 1-6. Inthis instance the distances D3 between panels in the same row, and thedistance D4 between panels in the same column are determined asdescribed above regarding the embodiment of FIGS. 1-5, namely are 5 and10 times the panel thickness, respectively.

The products illustrated and described have been described in terms ofmaps. It will be apparent that other products may be similarlyconstructed to provide advantages as described herein, such as, forexample, gameboards on which suitable graphics are provided. It willalso be clear that rectangular panels of a variety of proportions may beused, ranging from panels which are square in shape to those which areconsiderably larger in one dimension than in the other, as is shown bythe drawings.

Maps and other like products of this invention provide a number ofsubstantial advantages over prior art laminated products. They providesubstantially more map coverage in a smaller package than prior artlaminated maps. They are 60% larger than conventional folding laminatedmaps when opened, providing room for other features and permittinglarger scale displays. Thus, a typical eight-panel map which folds intoa 41/4"×9" stack may provide a full open display which is approximately17"×18". This is a comfortable size to work with, while permittingfolding to a standard United States map size which means it is easy tostore in cars, purses, pockets or briefcases. Foldable maps inaccordance with this invention are tear, spill, weather andwater-resistant and are long-lived. They may be temporarily marked witha marker and erased.

Maps and other laminated products in accordance with this invention maybe made by a laminating process which will now be described. It will beunderstood that the laminating sheets may be provided with an adhesivewhich, under heat and/or pressure, will permanently bond the laminatingsheets to the paperboard during the laminating process.

In accordance with an exemplary process of the present invention whenused to make a map, paperboard is printed on each side with suitableintelligence including cartographic intelligence and other selecteddisplay materials such as area identification, street listings, etc. Theprinted paperboard may also provide "selvage" areas around the border(See FIG. 8) as well as zones in which spaces D1 will be provided, whichzones are printed with narrow zones of duplicate intelligence so that ifthe spaces cut vary laterally, within limits all of the desiredintelligence will be displayed. This is as shown in FIGS. 11A and 11Band will be explained later.

As shown by FIG. 8 a printed master paperboard sheet M having a forwardleading edge, a parallel trailing edge and opposite perpendicular sideedges, is first cut, such as by die-cutting, to remove a narrowtransverse paperboard segment from the middle of sheet M along a zonecorresponding to space D2. Connecting segments 42 at the ends of theresulting gap 40 are left to temporarily hold rows R1 and R2 together.The master paperboard sheet M is then advanced, as along a table andbetween lateral guides 50 (FIG. 9), to a pair of drive rollers 52 havingsurfaces which firmly grip the leading edge of the master sheet M tofeed and drive the master sheet forwardly in a first direction. Thesurfaces may be rubber, nylon or other suitable materials. A series ofcutters 54, such as rotary blade cutters mounted on roller 55, areprovided. Pairs of cutters 54 continuously cut and slit strips of wastepaperboard W between adjacent panels P1 and single cutters 54 remove aborder of selvage S at each side edge of sheet M. As shown in FIG. 10,the cutters 54 may cooperate with suitable anvils 56 to sever the stripsfrom the paperboard sheet M. The strips W and selvage S are engaged, asby a diverter 58, which forces and drives the strips and selvagedownwardly to waste. The strips W removed by cutters 54 between adjacentpanels correspond to the spaces D1 illustrated in FIG. 2.

Although efforts are made to precisely cut the paperboard along spacededges E of intelligence produced by the printing of the paperboard, thatdoes not always successfully occur. To compensate for that, the zones tobe removed are printed to accommodate to that circumstance as will nowbe described.

Referring to FIGS. 11A and 11B, representative adjacent panels A and Bto be formed from a master sheet M are shown. Panels A and B may beconsidered as a pair of panels P1. These panels A, B are spaced apart bya distance G and if cut exactly along their confronting edges E toprovide a space D1 will show complete contiguous adjacent subjectmatter. The pairs of cutters 54 are spaced to cut out a strip of waste Wexactly equal to distance G. However, because of slight misalignments,frequently the paperboard sheet is offset laterally so that the cutters54 will cut out a strip W equal to distance G but either to the right orleft of the confronting edges E, which as shown in Figs. 11A and 11B,are equidistant from the centerline CL between edges E. To compensatefor that misalignment possibility, a duplicate of segment A'A' of themap portion on panel A is printed adjacent to edge E of panel B asillustrated in FIG. 11A and a duplicate segment B'B' of the map portionon panel B is printed adjacent to the edge E of panel A, as illustratedin FIG. 11B. Thus, if the cutters 54 remove a strip W which is notcentered on the centerline CL, namely is offset somewhat, as long as thecut is not offset by more than one-half of the width of the strip W tobe removed, a complete representation of the map intelligence willremain at space D1.

The drive rollers 52 continue to drive the master sheet M toward andinto the nip of the laminating rollers 60 at which laminating sheets Lare presented to the upper and lower surfaces of the developing panelsof the master sheet M. The laminating rollers 60 then take control ofthe sheet M and draw it and the laminating sheets L therethrough.

The drive rollers 52 continue to drive the master sheet M forwardly aswell, and in a manner which does not interfere with the operation at thelaminating rollers 60. Rollers 52 continue to control the relativepositioning of the panels P2 to each other as the cutters 54 continue toslit and cut the master sheet M. At the time the cutters 54 reach thespace D2 and sever segments 42, the temporary connection between theadjacent rows R2, R1, the portion of the sheet M trailing the die-cutspace D2 will be under the control of rollers 52 and the forward ends ofthe panels of the row R2 will be under the control of the rollers 60. Tomaintain such control, it will be appreciated that the length N' is lessthan length N (See FIG. 9). In that manner the relationship of the driverollers 52 and laminating rollers 60 to the panels of the masterpaperboard sheet will be maintained. Because rollers 52 are driven insynchronization with the laminating rollers 60, the developing mastersheet panel elements P1 remain spaced as desired from the paperboardelements of panels P2 and the columns of pairs of panels P1, P2 remainproperly aligned. The paperboard of row R1 remains under the control ofthe rollers 52 until after the panels P1 are fed into the nip providedby rollers 60. Thus, the array of paperboard panels is located preciselyas desired, and the relationships of the intelligence on the panels andthe paperboard elements of the panels in the laminated product areaccurately and suitably located and maintained.

The laminating films L are typically wider than the width of the panelsof rows R2 and R1. As such, after the laminate is formed (after thetrailing edge passes through the laminating nip), the edges may betrimmed by cutters (not shown) as schematically illustrated by FIG. 8 toprovide finished edges, such as a sealed border, or the laminate may betrimmed to provide a butt edge of paperboard and laminating film (asillustrated by FIG. 5) at the side edges. The leading and trailing edgesmay be similarly trimmed to provide a butt-cut border as illustrated byFIG. 5, or they may be trimmed to provide sealed, waterproof borders.

From the foregoing, it will be apparent that numerous modifications andvariations can be effected without departing from the spirit and scopeof the present invention. It will be appreciated that the presentdisclosure is intended as an exemplification of the invention, and isnot intended to limit the invention to the specific embodimentsillustrated and described. The disclosure is intended to cover by theappended claims all such modifications as fall within the scope of theclaims.

What is claimed is:
 1. A laminated product having a plurality ofadjacent rectangular panels each displaying imprinted intelligence, eachsaid panel comprising an individual rectangular paperboard sheet, eachsaid paperboard sheet having a pair of opposite display surfaces andhaving outer perimetric edges, said paperboard sheets together defininga rectangular array, and outer perimetric edges of said sheets togetherdefining an outer boundary for said rectangular array of paperboardsheets, said laminated product further comprising a first transparentsheet covering a first surface of said array of paperboard sheets and asecond transparent sheet covering the second surface of said array ofpaperboard sheets, said transparent sheets joining all of the paperboardsheets into said integrated laminated product, said transparent sheetsbeing continuous between the outer boundary of said rectangular array,being coextensive with all of said paperboard sheets, and beingcharacterized by the absence of slots between said paperboard sheets,said panels being arranged in at least two rows of plural panels and aplurality of columns of panels, each column including one panel fromeach row, each pair of paperboard sheets in a row being spaced apartfrom each other by a distance which is at least equal to twice thethickness of a panel, and each pair of paperboard sheets in a columnbeing spaced apart by a substantially greater distance than at leasttwice the thickness of a panel, said substantially greater distancebeing at least equal to the thicknesses of the total number of panelscomprising the laminated product, whereby when the pairs of panels inthe columns are accordion-folded in the direction of the columns, andare then folded to cause the panels of one row to overlie the panels ofthe other row, the product will so fold into a compact stack withoutsubstantial resistance to movement into that configuration and will besubstantially flat, and when the panels are temporarily folded intoother single stack compact random arrays, such arrays will be compactand substantially flat, all so that any display surface of any panel maybe temporarily easily displayed for viewing, and whereby all foldingoccurs between the paperboard sheets and depends entirely upon thefolding of said transparent sheets and ripping and tearing of saidtransparent sheets is avoided because of the absence of slots in saidtransparent sheets between said paperboard sheets.
 2. The laminatedproduct of claim 1, and wherein said product is a map.
 3. The laminatedproduct of claim 1, and wherein said product has two rows, and each rowhas at least four rectangular panels.
 4. The laminated product of claim1, and wherein the paperboard sheet of each panel is entirely separatefrom each other paperboard sheet of every other panel.
 5. The laminatedproduct of claim 1, and wherein the distances between the pairs ofpaperboard sheets in a row and the pairs of paperboard sheets in acolumn are between 10 to 30 percent greater, respectively, than twotimes the thickness of a panel and the thicknesses of the total numberof panels.
 6. The laminated product of claim 5, and wherein said productis a map.
 7. The laminated product of claim 5, wherein said map has tworows, and each row has at least four rectangular panels, each paperboardsheet being entirely separate from each other paperboard sheet.
 8. Thelaminated product of claim 7, and wherein said map panels are about 41/4inches by about 9 inches in size.